Method of constructing a reinforced concrete dwelling

ABSTRACT

A method is disclosed for the method of building a structure. The method includes laying a foundation; running tubing within a column form; pouring the concrete into the column form; and forming walls so as to define the structure. The walls are formed from concrete columns separated by foam. The concrete attaches to the insulation as the concrete sets. A roof is also included and formed from a plurality of sections. The roof is placed in communication with the walls.

BACKGROUND

1. Field of the Invention

The present application relates generally to the construction of a dwelling, and in particular to a method of building a reinforced concrete structure.

2. Description of Related Art

Many homes and buildings in America are built using common building materials. Typical practices include a concrete foundation and wooden framing for the walls. The roof is constructed of more wooden framing. Exterior textures are added to the walls and finished interior textures are usually sheetrock and plaster. Roofs generally use a composite roof shingle. Insulation is typically added, in varying depths, to the walls and ceilings in an effort to act as a thermal barrier.

A number of disadvantages exist with typical homes and buildings. First there is an added fire risk by using wooden framing. As an alternative, some buildings are constructed using metal framing studs. These are not preferred due to cost. Secondly, costs of insulation and the effectiveness of the insulation is varied and limited. Air gaps in the walls where insulation didn't cover can act as thermal passageways making it difficult to regulate the temperature inside the home/building. Thirdly, these types of homes are susceptible to wind damage from strong storms. Tornadoes can demolish a home easily. Fourth, costs of construction are relatively high compared to other types of materials available to the industry.

Although great strides have been made with respect to home and building construction, considerable shortcomings remain. A new method of constructing buildings is needed that allows for better thermal regulation inside the building, is more resistant to storm damage, resist fire danger, and is cheaper to build thereby becoming more affordable for the public to own.

DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the application are set forth in the description. However, the application itself, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings.

FIG. 1 is a side section view of a portion of a concrete reinforced structure built according to a method of the present application.

FIG. 2 is a front view of an exemplary wall structure in the concrete reinforced structure of FIG. 1.

FIG. 3 is a top view of the wall structure of FIG. 2.

FIG. 4 is a partial section view of a roof structure of the concrete reinforced structure of FIG. 1.

FIG. 5 is a chart of the method of constructing the concrete reinforced structure of FIG. 1.

While the application is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the application to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the application as described herein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Illustrative embodiments of the preferred embodiment are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present application, the devices, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the device described herein may be oriented in any desired direction.

The method in accordance with the present application overcomes one or more of the above-discussed problems commonly associated with conventional methods of building structures. Specifically, the method of the present application is configured to provide a reduction in flammable products used in the method of building a dwelling and thereby reducing fire dangers. The method is configured to provide greater control in regulating the thermal effectiveness of the structure by eliminating gaps between the structure and the insulation. The method is also configured to increase the structural strength of the dwelling to resist storm damage. Each of these benefits are provided while the method is used to work with building materials that are more cost effective to a builder and a home owner. These and other unique features of the device are discussed below and illustrated in the accompanying drawings.

The method will be understood as to its operation, from the accompanying drawings, taken in conjunction with the accompanying description. It should be understood that various components, parts, and features of the device may be combined together and/or interchanged with one another, all of which are within the scope of the present application, even though not all variations and particular embodiments are shown in the drawings. It should also be understood that the mixing and matching of features, elements, and/or functions is expressly contemplated herein so that one of ordinary skill in the art would appreciate from this disclosure that the features, elements, and/or functions of one embodiment may be incorporated into another embodiment as appropriate, unless otherwise described.

The method of the present application includes steps taken when building a structure, such as a home or other building, to make the home more cost effective, safer, and efficient. Like most structures a foundation is preliminarily laid, followed by the formation of a number of walls, and finished by a roof. The type of materials, manner of construction, and steps to link each of these together is defined in more detail herein.

Referring now to the figures wherein like reference characters identify corresponding or similar elements in form and function. The following Figures describe a method of constructing a dwelling, home, or building (i.e. a structure). FIGS. 1-4 illustrate the different facets of the structure that is built by the method of the present application. FIG. 5 shows some of the various steps used to construct the structure of FIGS. 1-4.

Referring to FIG. 1 in particular, a partial side section view of the reinforced concrete structure 101 built according to the method of the present application is illustrated. Structure 101 includes a roof structure 103, a wall structure 105, and a foundation 107. Wall structure 105 is laid or formed on foundation 107 after foundation 107 is formed. Once wall structure 105 is formed and able to bear weight, roof structure 103 is formed and assembled. Both structures 103/105 are formed on location and in position within the structure. Concrete is generally poured into forms and in place.

Referring now also to FIG. 2 in the drawings, a front view of an exemplary wall structure 105 is illustrated. Wall structure 105 is configured to include a combination of reinforced concrete and insulation. The concrete is used because it is relatively cheap and provides an extreme level of strength. The insulation is used to provide energy efficiency so as to assist in regulating the temperature within the structure. Furthermore, wall structure 105 includes an interior surface treatment 109 and an exterior surface treatment 111.

Wall structure 105 includes a plurality of pillars of reinforced concrete 113 and a section of insulation 115 configured to span the distance between pillars 113. The insulation provides the energy efficiency while the pillars provide the strength. Pillars 113 may be reinforced with any type of known method and product commonly used in the industry. A common method/product is rebar. The section of insulation 115 is formed from ready to assembly blocks or sheets of insulation that may be interlocked or stacked one with the other. This is depicted in FIGS. 2 and 3 by the use of dashed lines through insulation 115. It is understood that the size and formation used to assemble the section of insulation 115 can be varied and is not meant to be limited to that which is depicted.

Pillars 113 are configured to be secured to foundation 107 through the use of one or more ties 117. Ties 117 are solid members configured to be placed within the form used to form concrete. The ties operate to tie adjoining members of concrete together. Although only a single tie 117 is shown at specific locations, it is understood that a plurality of ties 117 may be used at each location joined together. Additionally, the shape is not herein restricted. Other shapes may be used, like a wire sheet perhaps. Ties 117 are also used at the tops of pillars 113 to join pillars 113 and roof structure 103. Ties 117 are also seen in FIG. 1 wherein their shape is shown such that they are angled at a selected point. The tie 117 is FIG. 1 is set within a pillar similar in form and function to that of pillar 113.

Furthermore, wall structure 105 is also configured to have piping 119 along selected routes. Piping 119 may pass through any pillar 113 and through any portion of insulation 115. Typically, piping 119 is used to pass electrical wiring and/or water to various portions of structure 101. These routes of piping 119 are pre-planned into the design of structure 101. Piping 119 is pre-located within the forms of pillar 113 prior to the pouring of concrete to create each pillar 113. Given the nature of insulation 115, routes may be formed in each section as needed at any time. It is preferred that such routes are formed at the time of constructing/orienting the insulation section so as to maintain tight clearances.

Referring now also to FIG. 3 in the drawings, a top view of wall structure 105 is illustrated. In this view, wall structure 105 is shown as further including interior surface treatment 109 and corresponding attachment members 121. Surface treatment 109 is configured to span across the face of insulation 115 and a plurality of pillars 113. Surface treatment 109 provides a smooth surface for an owner to utilize. Use of surface treatment 109 avoids the need for internal framing from metal or wood studs. Treatment 109 includes the use of a wire mesh and concrete, wherein the concrete is sprayed onto the wire mesh. Any thickness can be achieved but a 1 inch thickness is suitable. The concrete surface is smoothed down for a simple finish. In order to assist in keeping surface treatment 109 against the face of insulation 115 and pillars 113, surface treatment 109 includes attachment members 121 which extend into pillars 113 from treatment 109. In this manner, members 121 act similarly to that of ties 117.

Referring now also to FIG. 4 in the drawings, a section view of roof structure 103 is illustrated. Roof structure is formed in a manner similar to that of wall structure 105. Roof structure 103 includes an insulation section 125 located between a plurality of reinforced concrete rafters 123. Rafters 123 and section 125 are similar in form and function to that of pillars 113 and section 115 respectively. An exterior surface treatment 111 is placed upon the exterior surface of roof structure 103. This surface treatment may be similar to that of interior surface treatment 109 wherein it includes a layer of concrete and mesh. The interior surface treatment of roof structure 103 is also similar in form and function to that of treatment 109. Differing finishes may be had but the overall concept of creating a layer of concrete is the same.

Referring back to FIG. 1 in the drawings, exterior surface treatment 111 is further described. Treatment 111 may be performed to create any typical or customary type of exterior finish currently known. For example, exterior surface treatment 111 may include a stucco finish with wire mesh. As seen in FIG. 4, exterior surface treatment 111 may include a layer of bricks 127. Exterior surface treatment 111 may optionally include a sub layer 129 composed of a concrete and mesh coating similar in form and function to treatment 109. Mesh from layer 129 may extend into pillars 113 as well for attachment similar to members 121. This provides added stability to wall structure 105 and further insulates wall structure 105 from the outside environment.

Referring now also to FIG. 5 in the drawings, a method of constructing structure 101 is illustrated. Structure 101 is built according to the method of the present application and is configured to increase in thermal efficiency, strength, and more resistance to storm damage all while reducing the costs of construction. The first step includes laying a proper foundation. The foundation is reinforced with one or more types of materials. A common material is rebar. Foundations may be of various shapes and sizes. Concrete is the preferred material and is ideal for is cost and strength characteristics. Once the rebar and other reinforcing materials are placed, the foundation is poured and permitted to set. The foundation is configured to provide one or more tie down locations that extend above the top level of the foundation after setting. These tie down locations are used to help secure one or more wall structures 105. The tie down locations include ties 117 which are set within the forms for the foundation prior to pouring. It is understood that ties 117 may be drilled, screwed, or nailed into foundation 107 after it has set as well. The ties 117 are configured to extend above a top surface of foundation 107.

After the foundation is set, wall structure 105 is formed. As stated previously, the walls are configured to primarily consist of concrete columns that are regularly spaced apart from one another, along with a foam insulation extending therebetween each column/pillar. Along the width of the wall, concrete columns are spaced apart by the foam, at some preselected distance. The distance between the columns/pillars may be a consistent value, such as 48 inches or 60 inches. First the insulation is built or placed in its proper position. Next, the forms for each pillar is prepared. Insulation 115 is configured to act as part of the form for each pillar. Additionally, the mesh for interior treatment 109 and even sub layer 129 may be located prior to pouring of the concrete for each pillar 113. Tubing 119 is routed within insulation 115 and selectively located inside the pertinent portions of the form of each pillar (if used). Plumbing may extend out from the foundation and coincide with the location of a pillar 113. Once all the tubing 119 and mesh layers are located, the concrete for pillars 113 are poured into the respective forms. Attachment members 121 and ties 117 are adhered to the concrete as it sets. The concrete penetrates into portions of the insulation and attaches itself to the insulation. This minimizes air gaps there between. Typically, the exterior walls are formed first, followed by the interior walls. The steps for each are the same.

The roof structure is formed on top of the wall structure. Roof insulation 125 is oriented above the wall structure and forms for a plurality of roof rafters are created. These are selectively reinforced and additionally coupled to ties 117. The roof insulation forms part of the rafter form, such that upon pouring of the rafters, the concrete attaches and penetrates a portion of the insulation, thereby removing or eliminating gaps of thermal passageways. The roofing panel is prewired for tubing 119 (i.e. for electricity and/or water) and is matched up with tie down locations placed in the walls. The roof is poured in place above the walls. The concrete is then poured in the roof rafters. Supports and wooden pillars may be used to help the roof hold its shape until the concrete is set. Both exterior surface treatment 111 and interior surface treatments 109 may be applied as desired.

The roof of the structure is built in sections and similarly to that of the walls. Insulation is used to help act as the form for the pouring of concrete sections. A mesh of rebar is laid out and insulation is fitted between the sections. The roofing panel is prewired for electricity and is matched up with tie down locations placed in the walls. The roof is poured in place above the walls. Supports and wooden pillars may be used to help the roof hold its shape until the concrete is set.

By spraying/pouring the concrete which forms the basis of surface treatments 111, 109, and sub layer 129, it is important to note that the wet concrete is able to mate with and bond to the face of insulation 115/125 (i.e. front/rear/exterior/interior face). Much like with the pillars penetrating or coupling to the insulation, these treatments and sub layer do the same; thereby minimizing thermal losses through air gaps.

Furthermore, the use of the ties between the foundation, walls, and roof are configured to strengthen the structure to resist storm damage. When completed, the foundation, walls and roof are considered one member effectively bonded and tied together. As noted earlier, various interior treatments and exterior treatments are available. Concrete is used as a material to provide rigidity to the structure and because it is more cost effective. The use of the concrete and foam together act to create a more complete seal for thermal regulation.

System 101 includes a number of advantages, such as at least the following: 1) increased rigidity from the effective tie downs between the roof, walls, and foundation; 2) increased thermal efficiency; 3) concrete poured against the foam to create and better seal; 4) lower cost to build; and 5) availability of standard finishes for the interior and the exterior.

It is evident by the foregoing description that the subject application has other significant benefits and advantages. The present method is amenable to various changes and modifications without departing from the spirit thereof. The particular embodiments disclosed above are illustrative only, as the apparatus may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. It is therefore evident any alterations, modifications, and all such variations are considered within the scope and spirit of the application. It is apparent that a method with significant advantages has been described and illustrated. 

What is claimed is:
 1. A method for building a structure, comprising: laying a foundation; forming a wall structure by: orienting a section of insulation along the foundation; creating forms for a plurality of pillars, the pillars located on opposing ends of the insulation, the insulation forming a portion of the form; running tubing within at least one of the forms for the passage of at least one of electrical wiring and water; and pouring concrete into the pillar form, the concrete attaching to the insulation so as to minimize air gaps there between; forming a roof structure and coupling it to the wall structure by: orienting a section of roof insulation between a plurality of forms for rafters, the roof insulation forming part of the rafter form, the roof insulation and the rafters being assembled on top of the wall structure; and pouring concrete into the rafter forms.
 2. The method of claim 1, further comprising: locating a tie relative to the foundation, the tie being secured to the foundation and configured to extend above a foundation surface.
 3. The method of claim 2, wherein the tie is formed within the concrete as the concrete sets.
 4. The method of claim 2, wherein the tie is coupled to the concrete after the concrete has set.
 5. The method of claim 1, further comprising: applying an interior surface treatment to at least one of the wall structure and the roof structure.
 6. The method of claim 5, wherein the interior surface treatment is a combined layer of mesh and concrete.
 7. The method of claim 6, wherein the concrete is sprayed over the mesh.
 8. The method of claim 1, further comprising: applying an exterior surface treatment to at least one of the wall structure and the roof structure.
 9. The method of claim 8, wherein the exterior surface treatment is brick.
 10. The method of claim 8, wherein the exterior surface treatment is stucco.
 11. The method of claim 1, further comprising: a sub layer between the wall structure and an exterior surface treatment.
 12. The method of claim 1, further comprising: an attachment member configured to secure an interior surface treatment to the wall structure. 